Ampcontrol OCS User manual

Version: 5, FEBRUARY/2020
Designed and manufactured in Australia by Ampcontrol Pty Ltd
OCS
OUTLETCASSETTESYSTEM
UserManual

Ampcontrol Pty Ltd –ABN 28 000 915 542
OCS USER MANUAL
MAG-182 Version 5 –FEB/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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WARNING!
The warning symbol highlights a potential risk of injury or death.
Please share these warnings with other operators.
CAUTION!
The caution symbol highlights a potential risk of damage to
equipment.
Please share these cautions with other operators.
NOTE
The note symbol highlights key information.
Please share these notes with other operators.
ENVIRO
The enviro (environmental) symbol highlights areas which may have an
impact on the surrounding fauna and/or flora.

Ampcontrol Pty Ltd –ABN 28 000 915 542
OCS USER MANUAL
MAG-182 Version 5 –FEB/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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Copyright Notice
The Ampcontrol OCS described in this document is the property of AMPCONTROL PTY LTD. It is
furnished under a license agreement and is to be used only in accordance with the terms of the
agreement.
No part of the hardware or documentation may be reproduced, transmitted, transcribed, stored in a
retrieval system, or translated into any language or computer language, in any form or by any means,
without prior written permission of AMPCONTROL PTY LTD.
Disclaimer
While every effort has been made to assure the accuracy and clarity of this document, AMPCONTROL
PTY LTD assumes no liability resulting from any omissions in this document, or from misuse of the
information obtained herein. The information in this document has been carefully checked and is
believed to be entirely reliable with all of the necessary information included. AMPCONTROL PTY LTD
reserves the right to make changes to any products described herein to improve reliability, function, or
design, and reserves the right to revise this document and make changes from time to time in content
hereof with no obligation to notify any persons of revisions or changes. AMPCONTROL PTY LTD does
not assume any liability arising out of the application or any use of any product or circuit described
herein; neither does it convey license under its patent rights or the rights of others.
Before You Begin
Thank you for purchasing the Ampcontrol Outlet Cassette System.
WARNING!
In the interests of safety and correct equipment operation, please
take the time to read and understand the content in this manual.
Ampcontrol Contact Details
7 Billbrooke Close, Cameron Park, NSW, 2285
P [phone] | F [phone]
EMAIL: [e-mail]
WEB: ampcontrolgroup.com

Ampcontrol Pty Ltd –ABN 28 000 915 542
OCS USER MANUAL
MAG-182 Version 5 –FEB/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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TABLE OF CONTENTS
1 SAFETY AND OTHER WARNINGS..................................................................8
1.1 Safe Use of Equipment..............................................................................8
2 RECEIVING AND STORAGE..........................................................................10
2.1 Receiving.................................................................................................10
2.2 Inspection................................................................................................10
2.3 Storage after Delivery..............................................................................10
2.4 Unpacking of Equipment..........................................................................10
3 PRODUCT OVERVIEW ..................................................................................11
4 INSTALLATION...............................................................................................14
4.1 General Warnings....................................................................................14
4.2 Mandatory Installation Practices ..............................................................15
4.3 Mechanical Arrangement.........................................................................16
4.4 Electrical Installation Information .............................................................17
4.5 External Accessories ...............................................................................18
5 COMMISSIONING AND CALIBRATION .........................................................19
5.1 Earth Leakage .........................................................................................19
5.2 Residual Voltage......................................................................................19
5.3 Earth Fault Lockout..................................................................................19
5.4 Earth Continuity.......................................................................................19
5.5 Insulation Test (High Voltage)..................................................................19
5.6 Over Current/Motor Overload Current Injection........................................20
5.7 Short Circuit Current Injection..................................................................20
5.8 Main Contactor Fail..................................................................................20
5.9 Voltage Measurement..............................................................................20
5.10 RTX.......................................................................................................20
6 PRODUCT OPERATION.................................................................................21
6.1 Outlet Control...........................................................................................21
6.2 Control of Resets.....................................................................................21
6.3 Internal Trips............................................................................................22
6.4 Events Log...............................................................................................23
6.5 Protection Element Parameters...............................................................26
6.6 Time and Date.........................................................................................28
6.7 Cassette Isolation & Earthing (OCS Only)................................................28
7 AS/NZS 2081:2011 PROTECTION FUNCTIONS............................................30
7.1 Earth Leakage .........................................................................................30
7.2 Residual Voltage......................................................................................31

Ampcontrol Pty Ltd –ABN 28 000 915 542
OCS USER MANUAL
MAG-182 Version 5 –FEB/2020
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7.3 Earth Continuity.......................................................................................32
7.4 Earth Fault Lockout..................................................................................34
7.5 Main Contactor Protection .......................................................................36
8 CURRENT RELATED PROTECTION FUNCTIONS........................................39
8.1 Inverse Time Protection...........................................................................39
8.2 Short Circuit.............................................................................................44
8.3 Current Balance.......................................................................................45
8.4 Under Current..........................................................................................46
9 OTHER PROTECTION FUNCTIONS..............................................................46
9.1 Under Voltage..........................................................................................46
10 SERVICE, MAINTENANCE & DISPOSAL.....................................................47
10.1 Equipment Service.................................................................................47
10.2 Equipment Maintenance........................................................................48
10.3 Disposal.................................................................................................48
11 SPECIFICATIONS ........................................................................................49
11.1 Cassette Specifications..........................................................................49
11.2 Protection Element Specifications..........................................................49
12 EQUIPMENT LIST ........................................................................................52
APPENDIX A: PROTECTION ELEMENT LOAD CURRENT TABLES................53
A1: Protection Element Full Load Current Table............................................53
A2: Protection Element TMS Table................................................................55
APPENDIX B: DRAWINGS................................................................................57
APPENDIX C: APPROVALS..............................................................................63

Ampcontrol Pty Ltd –ABN 28 000 915 542
OCS USER MANUAL
MAG-182 Version 5 –FEB/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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TABLE OF FIGURES
Figure 3.1: Ampcontrol Outlet Cassette System (OCS)..........................................................................11
Figure 3.2: Ampcontrol Fixed Cassette System (FCS)............................................................................12
Figure 4.1: 2-Way OCS Dimensions (Pictured with 2 Cassettes Installed)..............................................16
Figure 4.2: 3-Way OCS Dimensions (Pictured with 3 Cassettes Installed)..............................................16
Figure 4.3: FCS Dimensions (Pictured with 5 Cassettes Installed) .........................................................17
Figure 4.4: Remote Termination Unit (RTX) ...........................................................................................18
Figure 6.1: Actuator position within chassis............................................................................................29
TABLE OF TABLES
Table 1: Definitions...................................................................................................................................7
Table 2: Event Log Entry Types .............................................................................................................23
Table 3: Outlet Parameter Descriptions..................................................................................................26
Table 4: Load Parameter Descriptions ...................................................................................................27
Table 5: Protection Element - Earth Leakage Trip Characteristics..........................................................30
Table 6: Protection Element - Earth Leakage CT Failure Trip Characteristics ........................................31
Table 7: Protection Element –Residual Voltage Trip Characteristics .....................................................31
Table 8 Protection Element - Earth Continuity Series Trip Characteristics..............................................33
Table 9: Protection Element - Earth Continuity Shunt Trip Characteristics..............................................33
Table 10: Protection Element - Earth Continuity Pilot Interlock Trip Characteristics................................34
Table 11: Protection Element - Earth Fault Lockout (EFLO) Trip Characteristics....................................35
Table 12: Protection Element –High Voltage Insulation Test Characteristics.........................................35
Table 13: Protection Element –Voltage Detection (Loss of Vacuum) Trip Characteristics......................36
Table 14: Protection Element –Frozen Contactor Trip Characteristics...................................................37
Table 15: Protection Element –Contactor Close Fail Trip Characteristics..............................................37
Table 16: Protection Element –External Open Trip Characteristics........................................................38
Table 17: Protection Element –Coil Voltage Detection Trip Characteristics...........................................38
Table 18: Protection Element –Over Current Trip Characteristics..........................................................39
Table 19: Protection Element –Motor Overload Trip Characteristics......................................................41
Table 20: Protection Element –Short Circuit Trip Characteristics...........................................................44
Table 21: Protection Element –Current Balance Trip Characteristics.....................................................45
Table 22: Protection Element –Under Current Trip Characteristics........................................................46
Table 23: Protection Element –Under Voltage Trip Characteristics........................................................46

Ampcontrol Pty Ltd –ABN 28 000 915 542
OCS USER MANUAL
MAG-182 Version 5 –FEB/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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DEFINITIONS
Table 1: Definitions
Term
Definition
Cassette
A Cassette is the unit that is installed within Outlet Cassette System (OCS)
or Fixed Cassette System (FCS). There are two types: FCS Cassettes and
OCS Cassettes.
Each Cassette houses a Protection Element, phase current transformers
and main contactor components.
CB
Circuit Breaker; Main circuit breaker that controls power to all outlets.
CBR
Circuit Breaker Relay; power relay within the Cassette Protection Element
to control the supply to the circuit breaker coil. The Protection Element’s
CBR output is designed for use with under voltage tripping coils.
FCS
FCS is the acronym for the Ampcontrol Fixed Cassette System.
MC
Main Contactor; the main power circuit opening device. Installed within the
Cassette, the main contactor is opened and closed in order to turn the
outlet on and off.
MCR
Main Contactor Relay; power relay installed within the Cassette Protection
Element to control the supply to the main contactor coil. All trip times
specified are to the opening of the MCR.
OCS
OCS is the acronym for the Ampcontrol Outlet Cassette System
Parameter Dongle
A small memory device which is used to store setting information for the
MEM and RTX modules which is attached to the wiring harness of the
installation.
Protection Element
The Protection Element is installed in each Cassette, providing a host of
protection functions for the outlet.
RTX
Remote Termination Device; Module that is installed at the machine end of
the pilot to provide machine identification and communications.

Ampcontrol Pty Ltd –ABN 28 000 915 542
OCS USER MANUAL
MAG-182 Version 5 –FEB/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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1 SAFETY AND OTHER WARNINGS
For safety reasons, the OCS must be installed, operated and serviced only by competent personnel.
Please read and understand this instruction manual completely before installing, operating or servicing
this equipment. Failure to install or operate this instrument in accordance with the instructions contained
in this manual may create hazardous operating conditions.
1.1 Safe Use of Equipment
The equipment supplied has been designed and manufactured to ensure safe operation. The equipment
must only be used within the design parameters.
The instructions within this manual must be observed as an aid towards achieving the safest possible
installation.
Persons responsible for installation, maintenance, or operation, must observe the following
instructions:
1.1.1 Changes to Equipment
Changes in the design and modifications to the equipment are not permitted. Unauthorised changes
made to the hardware or operating firmware will void the manufacturer's warranty, and may
compromise the integrity of the system into which it is installed and other connected equipment.
1.1.2 Equipment Knowledge
Experience with, or understanding of, this equipment is essential for the safe installation and removal of
the equipment. Therefore, please read and understand this manual prior to use. Competency based
training courses are recommended and are available on request.
1.1.3 Manual Handling
Precautions have been taken to ensure all equipment is safe to handle and free from sharp edges.
However care should always be taken when handling enclosures and gloves should be worn.
1.1.4 Installation
Correct operation and safety depend on the OCS and associated equipment being installed correctly.
Mechanical and or electrical installation and maintenance of plant and equipment must only be carried
out by appropriately qualified personnel and must be tested thoroughly prior to operation.
1.1.5 Operation
As safety depends on the OCS functioning correctly it is highly recommended that all safety functions
of the OCS be periodically tested to ensure correct operation.

Ampcontrol Pty Ltd –ABN 28 000 915 542
OCS USER MANUAL
MAG-182 Version 5 –FEB/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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1.1.6 Certification
WARNING!
To comply with the Conditions of Certification, ensure full serviceable
life of the product, and avoid nullifying the warranty, it is essential to
exercise great care with the installation, use and storage of the system
components. Failure to comply with the Conditions of Certification may
seriously compromise the integrity of the system and/or its components,
and the consequence could be fatal. The user must ensure that the
"Special Conditions" outlined in the certificate and associated
attachment is met or the certificate (and the I.S. rating) will not be valid.
Refer to the relevant section of the safety file for copies of certificates of conformity outlining the
special conditions of the certification for the explosion protected equipment or components.
The latest certificate and its associated attachments outlining the special conditions of the
certification are maintained and available on the IEC Ex Website: http://iecex.iec.ch.

Ampcontrol Pty Ltd –ABN 28 000 915 542
OCS USER MANUAL
MAG-182 Version 5 –FEB/2020
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2 RECEIVING AND STORAGE
2.1 Receiving
All possible precautions are taken to protect the equipment against damage or losses during shipment,
however before accepting delivery, check all items against the packing list or bill of loading. If there is
evidence of physical damage, notify Ampcontrol immediately.
Notify Ampcontrol immediately in case of any discrepancies to the packing list. Keep a record of any
claims and correspondence. Photographs are recommended.
Where practicable do not remove protective covers prior to installation unless there are indications of
damage. Boxes opened for inspection and inventory should be carefully repacked to ensure protection of
the contents or else the parts should be packaged and stored in a safe place. Examine all packing
boxes, wrappings and covers for items attached to them, retain and store any approval documentation
for your safety file as applicable prior to wrapping being discarded.
2.2 Inspection
Equipment that is found to be damaged or has been modified away from its published specification must
not be used. Please contact Ampcontrol if the equipment is suspected to be different than that ordered or
if it does not match the published specifications.
2.3 Storage after Delivery
When the equipment is not to be installed immediately, proper storage is important to ensure protection
of equipment and validity of warranty.
All equipment should be stored indoors between 0-40˚C, preferably on shelves and protected from
moisture and sunlight.
2.4 Unpacking of Equipment
The method of packing used will depend on the size and quantity of the equipment. The following
cautions should be interpreted as appropriate.
CAUTION!
Take care when unpacking crates as the
contents may have shifted during transport.
ENVIRO
The disposal of packaging materials, replaced parts, or components
must comply with environmental restrictions without polluting the soil,
air or water.
Ensure that any timber and cardboard used as packaging is disposed
of in a safe and environmentally responsible manner.
Where possible, dispose of all waste products i.e. oils, metals, plastic
and rubber products by using an approved recycling service centre.